Moore Business Forms, Inc.

Moore U.s.a., Inc.

Moore North America, Inc.

Moore Wallace North America, Inc.

Thomas P Nash

Eric V Palmer

Nancy G Mitchell

Robert E Grabau

John R Soltysiak

Adele C Shipston

Jeffrey J Boreali

Scott A Moeller

Myron C Heeb

Michael C Maier

Frank C DeReu

Stanley C Chess

Joseph T Duffy

Carolyn M Larson

Michael C Hausladen

Stephen Michalovic

James M Schweitzer

Daniel G Shenk

Radio frequency identification labels are made in a high speed and effective manner in a variety of different ways utilizing a number of different sources of RFID inlets, each inlet including an antenna and a chip. A plurality of webs are matched together and RFID labels are die cut from the webs, to produce lined RFID labels. Alternatively linerless RFID labels are produced from a composite web with a release material on one face and pressure sensitive adhesive on the other, the labels formed by perforations in the web.

RFID manufacturing concepts

A composite containing an RFID can be mounted on, in, or adjacent a metal object without de-tuning of the antenna of the RFID. The composite includes a first RFID or a EAS device-containing layer, and a foamable material layer held in proximity with the first layer. The foamable material layer expands in size and reduces in density when subjected to external stimuli, such as heat or microwaves. The foamable layer may comprise an intumescent material, and may have RF radiation-absorbing material filler. Pressure sensitive adhesive, when the composite is in a label form, may be used to mount the composite on or adjacent a metal object after printing of the printable surface of the composite, and the foamable material layer is subjected to the external stimuli after printing and either before or after mounting on or adjacent the metal object.

RFID composite for mounting on or adjacent metal objects

Radio frequency identification elements, including linerless or lined labels, are produced with enhanced effectiveness. The antenna is printed with conductive ink or toner, and cross-over may be provided by spot printing a non-conductive material over a portion of the antenna and then printing a conductive cross-over element on the non-conductive material. Typically the antenna is printed on one face of a web, and the radio frequency identification chip is moved into contact with the opposite face of the web so that the contacts penetrate the web and engage the antenna so that the web material acts as a dielectric. Alternatively part of the antenna on the first face may be over-printed with a non-conductive material and the chip attached to the first face passing through openings in, or penetrating, the non-conductive material to engage the antenna. A protective substrate or coating is provided on at least one of the chip and antenna, for example by heating heat expandable microspheres, or applying a substrate having hot melt adhesive. The antenna may be printed with a printing media comprising a carrier including resin and wax and containing conductive material in it, and by heating the carrier so that it becomes fluid and is applied as a thick film on the substrate, and by allowing the carrier to cool so as to provide a conductive antenna. The printing may be accomplished at a speed of about 500 feet per minute or more.

Radio frequency identification tags and labels

A label applicator, easily mounted on a desktop in association with a label printer, has a compact configuration with no external power requirements since the components are electrically powered and the power is received from the printer. Preferably the label does not move during application, providing a high degree of accuracy and placement. The applicator may be used with both linered and linerless labels and associated printers, and uses inexpensive components. Positive stops are provided for stopping the movement of a label into the applicator housing, and the manual movement of a mailpiece into the applicator housing. Sensors sense the label and the mailpiece when accurately aligned, and cause actuation of a linear solenoid with tamp pad to move the mailpiece vertically upwardly into contact with the label pressure sensitive adhesive. The label is held in place in the desired position by one or more electric fans exhausting air from the opposite face of an apertured plate from the label.

Semi-automatic mailpiece printer/label applicator

A combined business form/identification card includes a sheet of cellulosic stock material having a barrier coating on a first portion of the sheet with an overlay of laser-printable varnish on the barrier coat. Lines of weakness are provided in the sheet in the area of the barrier coat and varnish to produce an identification card detachable from the sheet. A second portion of the sheet has indicia imaged thereon.

Identification card and method of making

A radio frequency transponder is adhered to a substrate forming a label or business form. The substrate has thermally sensitive material whereby the substrate and transponder can be conveyed through a thermal printer for printing variable or non-variable information on the web. The transponder is provided in web form and separated from the web for application to the substrate. In a further embodiment, plural plies of business forms are provided and transponders separated from a web of transponders are disposed by the plies prior to separation of the plies into discrete forms, each carrying a transponder.

Method of forming labels containing transponders

Linerless labels are produced by feeding a tape having a release coated face and an adhesive face to a hardened anvil vacuum cylinder, utilizing a non-stick circumferential surface feed roll. A knife blade on a cutting cylinder is rotated into contact with the tape at the anvil cylinder to cut the tape into linerless labels, and release liquid is applied to the blade after each cut. From the anvil cylinder the labels are deposited on a plurality of spaced conveyor tapes of circular cross section with the adhesive faces contacting the conveyor tapes. A vacuum chamber assists in holding the labels on the conveyor tapes. The release coat faces of the labels conveyed by the conveyor tapes may be heated and then printed with hot melt ink from an ink jet printer. The labels are separated from the conveyor tapes using a peeler roll and non-stick stripper rings, and then immediately contact a moving web or other elements to which they are to be applied, with the label and web passing through nip rolls to activate the pressure sensitive adhesive.

Linerless label printer applicator

A thermal printer prints linerless labels in such a way that printer components will not stick to the adhesive face of linerless labels. Substantially stationary printer components, such as a label guide, transport plate, front panel, and stripper blade, preferably have the adhesive face engaging surfaces thereof plasma coated so that adhesive will not stick to them. An optional cutter provided downstream of the stripper blade also has plasma coated surfaces. A driven platen roller has a surface thereof coated with or covered by a high release silicone, which will not stick to the adhesive, but has high friction characteristics to facilitate drive of the labels. In a direct thermal printer, a plasma coated tear off surface is downstream of the driven platen roller, and stripper belts, a second roller with O-rings, and the like are provided to prevent the labels from wrapping around the driven platen roller. One or more sensors may also be provided for controlling drive of the platen roller in response to the position of registration marks on the linerless labels.

Linerless label printer and transport system

Linerless labels are dispensed from a roll and detached along perforation lines using a set of low speed rolls, a set of high speed rolls, and a breaker blade between the sets of rolls. The label-engaging tip of the breaker blade, and at least one roll of each sets of rolls, has a surface that will not stick to the adhesive associated with the linerless labels. One or more conveyor belts, also with non-stick surfaces, may transport the linerless labels from the low speed rolls to the high speed rolls, and transport detached labels away from the high speed rolls. A sensor downstream of the high speed rolls senses the presence of a detached label, and then shuts down both sets of rolls. The apparatus may be operated in an automatic mode so that when a detached label is manually removed from the high speed rolls both sets of rolls automatically start up again, or in a manual mode that requires the operator to activate a switch to restart the detacher each time.

Detaching linerless labels

Linerless labels are constructed in such a way that when they are manually dispensed they do not tear, but rather rip (separate cleanly) along predefined perforation lines. This is accomplished by providing those cuts of the perforation lines that intersect the slits or side edges of a composite web of linerless labels (and thus the side edges of individual labels when dispensed) have a length great enough to facilitate the start or end of ripping action. The length of each of these end-edge/slit intersecting cuts is at least twice (preferably at least four times) as great as the normal cuts of the alternating cuts and ties forming a perforation line, typically having a length of between about 0.125-0.25 inches (and spaced from each other between about 0.5-1.0 inches), when each of the standard cuts has a length of about 0.012-0.018 inches.

Linerless labels with extended cuts in cross-perforations

Linerless labels in a continuous web, in roll form, are dispensed. The roll is mounted for rotation by a vertical shaft, and periodically a drive roller with conveyor tapes wrapped around it is rotated to pull the web from the roll in an amount sufficient to unwind approximately one length of label from the roll. The adhesive face of the web engages the circumferential periphery of the drive roller and the conveyor tapes past the drive roller, the exit roller effecting separation of the leading label from the conveyor tapes. An idler roller engages and tensions the web between the roll and the drive roller, and a knife blade is mounted at about the point that the web leaves the drive roller. The components are disposed so that the web engages at least about 170 degrees of the circumferential periphery of the drive roller, with the adhesive face contacting the drive roller circumferential periphery and conveyor tapes. First and second optical sensors sense marks on the web to start and stop rotation of the drive roller so as to unwind one label at a time from the roll, and the roll is automatically braked to prevent the roll continuing to unwind when driving action by the drive means is interrupted.

Growing community of inventors

Getzville, NY, United States of America

Thomas P Nash